PE400×600復擺顎式破碎機的設計【含10張CAD圖紙+文檔全套】

喜歡就充值下載吧。。資源目錄里展示的文件全都有，，請放心下載，，有疑問咨詢QQ:414951605或者1304139763 ======================== 喜歡就充值下載吧。。資源目錄里展示的文件全都有，，請放心下載，，有疑問咨詢QQ:414951605或者1304139763 ======================== 高速機床的高精密加工 摘要 目的：現(xiàn)代機床加工精密產品的三維加工的磨削速度超過20000轉每分鐘。硬加工和柔性加工的差異對機床的概念有影響。剛度和硬度的特性和變量是影響加工零件的精度和質量的原因。 設計/方法/途徑：本文介紹了一些有趣的具有不同概念的現(xiàn)代機床如：DCG (Drive in Centre of Gravity - Mori Seiki), LAF (Look Ahead Function on machine - Sodick),高速為20000-60000轉每分鐘，線性驅動等。從想法到加工零件的轉變方式將會被演示。 結果：為了達到高精度，滿足機床上許多需要的功能是必須的。結果表明加工零件也取決于加工材料（硬度、結構、晶體尺寸）。 研究局限性/含義：工程師的工作是準備與CAD-CAM軟件相關的最優(yōu)的數(shù)控程序。在提到的所有因素后加工和測量工件。 創(chuàng)意/價值：對比預測的測量結果，讓我們知道事實和對高精度產品的決定。 關鍵詞：制造與加工；加工；高速機床；精密加工；精密產品；柔性加工；硬加工 1 簡介 現(xiàn)代機床的一些細節(jié)包括超模塊，如旋轉工作臺、精密高轉速主軸、棒料庫、刀具庫、工件庫、激光零點測量系統(tǒng)、診斷過程的切削力測力機、頻率傳感器、聲響傳感器等[1]。加工時為了連接所有的模塊，機床的計算機必須是最優(yōu)秀的。計算機中的軟件如神經網絡、遺傳算法、遺傳編程、預測功能，這些都是用來保證加工過程中的最優(yōu)切削參數(shù)[2]、[3]。世界各地的許多切削機床的制造商提供了機床空載時的精度水平。為了獲得高精密產品，我們需要高水平性能的車床。性能越好，車床的價格也越高。頂級機床的價格是500000到1000000歐元，它的價格超過了三軸機床。帶有驅動工具的三軸銑床和車床價格低于400000歐元。 小型舊機床的傳統(tǒng)加工—沒有現(xiàn)代化的高速，在個體制造業(yè)或刀具制造業(yè)也是非常有用。上面提到的機床價格低于200000歐元。它們大部分不能達到高速區(qū)，高速區(qū)是由更多的元素定義的，這將在這篇文章的下面章節(jié)給出。3D凹印拋光對獲得較低的表面粗糙度是一項非常特殊的工作。這一工作耗時的主要方面是操作。那是因為它的自動化與驅動拋光的刀具和減少特殊切削技術的選擇有關。所以確保選擇球頭銑刀、低切削深度、小進給量和很高的速度是必要的。因為技術是重要的軟件和控制器，所以在自學控制器的基礎上，它包括了復雜的優(yōu)化的切削條件的大量知識[4,5]。自動進給最小化在使用3D磨具靠近表面加工和拋光時是很有用的。 2 現(xiàn)代切削機床的內容 我們所提到的模塊也是有適應性。旋轉工作臺在工件自動夾緊裝置的情況下是更有效的。我們已經實現(xiàn)設計和工藝[6]。圖1給出了夾緊裝置上相關液壓控制的概念原理圖。下圖給出了機床電源,動力裝置和空氣和液壓介質的控制系統(tǒng)。 圖1銑床上介質流從信號源到工作板的原理展示 切削機床擁有高生產率，那是因為它享有現(xiàn)代傳統(tǒng)系統(tǒng)的60支座床身等級作為臥式和立式切削機床的新概念，如圖2。配有驅動刀具和雙側主軸切削機床的生產率也高。由于增加軸Z1、Z2和軸C1、C2，生產率比常規(guī)車床的生產率提高5-7倍。 立式車床也是集成化加工的新概念，與臥式車床相比，它的原理晶片有更好的運轉。圖2是工件在主軸的下面。這也有可能是相對的，主軸在上面，切削刀具在旋轉器和串聯(lián)刀具夾緊系統(tǒng)上移動。想這樣的機床會更精確、更精密、更高效。 圖2有兩個旋轉臺、輔助軸承和Y軸的臥式車床和立式車床 圖3穩(wěn)健的水平加工中心 穩(wěn)健的水平加工中心，如圖3所示的多軸機床的模塊和結構的粗糙概念。B軸稱為水平調節(jié)控制軸4。它能夠加工三維工件的復雜形狀。因為急需要機床，所以我們有必要為機械加工準備有效的編程工程師。來自低等教育的普通管理工人不但不能提供最優(yōu)的加工時間，而且還會提高生產成本。 最新車床的床身低于60度。如圖4，圖5這樣的角度給切削力組件的假設提供了最優(yōu)解。振動是有限的，芯片流同樣也是有規(guī)定的。下面的原理圖介紹了兩個主軸、兩個旋轉臺和驅動刀具。在相反面加工的同時切削力會得到補償。 圖4擁有兩個旋轉臺和輔助軸承的臥式車床的基本結構 圖5擁有兩個旋轉臺和相對主軸的臥式車床的基本結構 最后的模型是多軸機床。該車床基本上包含了所有可能的模塊和軸。由于主軸的左右兩面，我們可以在沒有后勤保證體系、雙向定位和夾緊的條件下在同一臺機床上完成產品的加工。銑床主軸生產的形狀復雜的產品與7臺不同機床的傳統(tǒng)生產不一樣。 圖6多軸加工中心 現(xiàn)代機床的工作原理和控制器的收集模塊如圖7所示，傳統(tǒng)的控制是數(shù)控，然后是計算機數(shù)控，最新的是中央處理器單元。所有的片段都與高速互聯(lián)網總線連接相連。高功率的電機是交流的數(shù)字伺服電機。 圖7帶有CPU技術的CNC控制的現(xiàn)代機床的控制原理 3 精密加工；理論和原理 精加工可以通過更多的方法完成，如傳統(tǒng)精細切削、光滑加工、滾動和后處理。傳統(tǒng)的方法是由鋒利的切削刃和小的進給率加工的。光滑加工是在切割刃切割較大半徑R的現(xiàn)代加工方法，進給率大，去除率8倍大。如圖8所示，通過觀察加工的時間來獲得所需的表面粗糙度是非常重要的。 圖8表面粗糙度和加工時間的對應圖 刀具材料對工件表面粗糙度有很重要的影響。特別是鍍膜的類型如TiN,TiCN,TiALN將較少刀具的磨損，如圖9。為了使刀具磨損最小，刀具的壽命要達到切削刃的標準。柔性切削加工會引起較好的滑動現(xiàn)象、更好的摩擦學接觸和更好的表面粗糙度。如用所提到的硬質合金刀具，表面粗糙度會顯著降低。 圖9不同鍍膜的硬質合金材料的銑刀的刀具壽命 球頭銑刀是精加工中最理想的切削刀具。那種尖頭銑刀可以使切削工件的硬度達到62HRc。刀具生產商們可以生產直徑為0.5毫米帶有兩個出屑槽的刀具。這些刀具的每個切削刃都很鋒利，而且還有非常精確的切削角。如圖10所示，當超過加工時間后切削刃將會磨損。正常的理論磨損是在刀具的出屑槽，但是在刀具的中間部分，也就是刀具的中心部分也會有一些破損[9]。原因是切削速度越小，積削瘤對磨損也有影響[10]。 刀具磨損和刀具的使用壽命取決于使用刀具的材料和刀具在加工表面上運行的次數(shù)。鍍膜為TiALN或TiN的W或VB處的刀具磨損是最好的，如圖11。 圖10球頭銑刀上的不同磨損形狀 圖11基于中間磨損的刀具磨損圖表 我們進行較多的實驗后，得到精密加工的最優(yōu)解是：多層鍍膜后的最后一層鍍膜是TiN[12]，這樣刀具就會有較低的摩擦系數(shù)。如圖12所示，刀具磨損是最小的。通常情況切削參數(shù)定義為a=0.1mm,f=0.05mm切削速度v=150-200m/min。只有20000到40000轉每分鐘的高速機床才有可能獲得較小刀具直徑。 圖12切削刃的刀具磨損 圖13告訴我們銑刀的圓頭尖端上自由表面的刀具磨損是較大的。切削刃損壞在銑刀圓頭尖端是可以看見的。出現(xiàn)這樣的情況就是機床參數(shù)的錯誤決定。在這種情況下，原因是進給率太高。為獲得更大的材料去除量只考慮增大進給率是不正確的。進給率必須保持很小。只有在更高的切削速度下我們才能獲得更大的材料去除量。 圖13切削刃上的磨損 4 拋光 加工表面的最后一步是拋光。它只有在幾何形狀要求的公差不超過2微米時有用。拋光不但費時，而且需要手工驅動拋光刀具。使用這種方法拋光時，拋光的時間會縮短，因為拋光段上的振動能量會幫助拋光。如圖14用模具進行閉合表面的最后精加工。結合精密研磨，拋光的時間從16小時縮短到3小時。 圖14用驅動刀具對工件手動拋光 使用不同的人造鉆石拋光凝膠也會縮短拋光時間。不同的凝膠用于不同的材料。拋光表面的硬度和粗糙度要求不同的人造鉆石尺寸。凝膠的流動性和粘性同樣影響拋光的時間，如圖15。 圖15人造鉆石拋光凝膠 如上所述，拋光刀具的振動能量是有用的。圖16是擁有超聲波頻率的拋光裝置。這意味著從14到21赫茲，當工人不集中于他的工作時，這樣的運動對表面是有危害的。在另一種情況下裝置上的力較小時，表面會由于預熱過高而損壞，這也是引起表面層再結晶的原因。 圖16超生波設備下的工件的手動/驅動/拋光 5 機床Sodick的精密性和性能的案例研究 機床的案例的研究是在模具工件產品上進行的。圖17是原理運動圖，這對產品獲得所需的形狀是必需的。作為第一次設計CAD的程序之一，輸入設計是新的或者舊的部分會有所改變。如果那樣，逆向工程將是數(shù)控編程快速編寫的正確方法。計算機輔助設計是建立在CAM軟件上的數(shù)控編程。故障是噴流的后置處理，這樣每臺機床的控制器就小多了。 圖18是許多現(xiàn)代模塊集成的現(xiàn)代化車床的案例。工件庫在加工中心的左邊，較強的控制系統(tǒng)在加工中心的右邊，最右邊是刀具庫。 圖17CAD-CAM測略模式的流程圖 圖18高速加工中心Sodick MC430L 正如我們前面所提到的許多現(xiàn)代模塊包括SODICK機械加工中心。其中的一個很有趣的解釋是因為高的進給速度對柔性加工很重要。這些特征保證了線性驅動電機。異步電動機的原理是基礎，它是從線性形狀的旋轉發(fā)展來的。永久磁鐵位于磁鐵板中的線性轉子處。電動機的外殼部分與電力和控制系統(tǒng)相連。這樣的話我們可以對移動區(qū)域的每一點精確而快速的定位。所有的三軸都有各自的線性驅動系統(tǒng)。轉臺由Y,X軸驅動，Z軸是主軸的進給系統(tǒng)。 下一個試驗是對所需部分的加工。一些重要的形狀、尺寸和公差是在計算機輔助設計上的設計圖上設計的。圖19是有趣的表面光柵，作為產品的特殊表面設計它越來越現(xiàn)代化。三維設計展現(xiàn)了藥片的不同形狀。加工產品需要許多相似的形狀，所以我們必須優(yōu)化切削技術。機床上的程序可以使刀具快速換刀，這種情況我們可以描述為切削操作。刀具換刀系統(tǒng)為藥片的小孔設計選擇球片刀具。主軸在刀具庫、零點檢測系統(tǒng)和加工工件之間以快速的進給速度移動。為實現(xiàn)刀具直徑的最佳切削速度所需的主軸上的切削工藝參數(shù)是28轉每分鐘。加工的進給速度是800-2300毫米每分鐘，進給速度大小取決于精密加工的要求。一些加工表面的細節(jié)如圖20和21。圖21所示的麻點形狀是很好的精密加工，在這種情況下，就不再需要手動拋光了，因為粗糙度值Ra=0.2微米。 最后必須應用加工拋光來獲得較好的表面粗糙度質量。用不同的切削參數(shù)和沒有磨損的刀具可以使表面粗糙度值為0.5微米。通常在這之后就不需要手工拋光了。 圖20加工表面的細節(jié) 用光柵制藥是有趣的。鋁模型的設計用于藥片包裝。 圖21加工表面的細節(jié) 生產機床的各廠家將機床特性作為機床的質量證書。尺寸的精密性很有可能控制機床所有的軸。我們會測量銑床主軸相對于轉臺間的垂直度。因為是微米測量，所以我們用最好最精確的測量設備。機床生產商保證X和Y軸的值為0.007毫米。通過測量SODICK，X軸的值為0.004毫米。在實驗室LABOD-盧布爾雅那大學的機械工程學院，我們得到了更好的結果：X,Y兩軸都是0.002毫米。圖22是提到的所有值的表格。 圖19測試產品案例研究的設計 圖22銑床主軸和轉臺間的垂直度 6 總結 現(xiàn)代的各類生產都基于切削技術參數(shù)的自我系統(tǒng)優(yōu)化。首先是在策略金字塔上最頂層的精密高速機床。 加工時間的減少對模具是必須的，模具加工是由擁有精密加工和拋光的現(xiàn)代高速銑床得到的。與傳統(tǒng)加工方法相比，閉模表面的調整時間大約減少15%。軟件測量的正確值0.05毫米比刀具的正確值大。這樣的話最好用五軸機床。閉模和快速產品（短周期的鋁合金鑄模）的較小公差要求額外的模具功能，如真空封閉雕刻。通過試驗和測量的偏差，我們將會額外的擴大技術數(shù)據庫。隨著越來越多和越好數(shù)據，我們可能使用CAM編程更加簡短的手工加工來適應閉模表面加工。 在汽車業(yè)中，部分材料的選擇和發(fā)展能夠在特定的力學性能和維修中遇到熱量的條件下繼續(xù)操作，與此同時維持它們的切削加工性能的特點能夠保證使用材料的經濟性。在切削刃處測試材料的加工會產生高溫，這將損害刀具材料的性能。市面上能買到的刀具材料只能用在速度小的條件下。更高級的刀具材料如CBN能夠在較高的切削速度的條件下生產高質量的零件。就像所有的刀具材料都一樣，在切削表面產生的極限溫度和壓力的條件下，它們的刀具壽命是有限的。因為所有的刀具材料在高速切削的條件下都會失去它們的硬度，所以為最小化刀具-工件和刀具-晶片接口產生的溫度制定特定的技術是必需的。在機械加工工藝的優(yōu)化中，必須考慮加工零件的客戶的需求。在汽車零件的加工中，表面質量、公差和生產率是客戶制定的要求，其中加工零件的表面質量的主要體現(xiàn)是表面粗糙度和毛刺外觀。 提高使用刀具的性能不但非常困難、昂貴，而且CBN刀具的圖層所含有的TiALN和TiN對有效的切削技術有很大的影響。未來，在高速條件下通過適當?shù)毒卟牧?、加工技術和刀具幾何形狀的合理選擇，對軟、硬材料的加工可以得到提高。 中期匯報表 學生姓名 XX 專 業(yè) XX 學 號 XX 設計（論文）題目 PE400×600復擺顎式破碎機的設計 畢業(yè)設計（論文）前期工作小結 一、畢業(yè)設計（論文）工作任務的進展情況 這段時間里，經過老師的悉心指導和自己的不懈努力，我確定了最終的設計方案，并且對破碎機的動顎部分進行了設計并繪制了零件圖，同時繪制了帶輪、肘板、飛輪、偏心軸等多個零件并對其進行了強度計算。 二、 設計中遇到的問題 在設計中，我對CAD的整體操作還不是很熟悉，螺紋的粗細實線也不是很清楚，還要進一步掌握Proe的使用方法 三、 下一步的打算 1完成接下來的破碎機的總裝圖和論文的收尾工作 2、為最后的答辯做好準備工作 指導教師意見 該生畢業(yè)設計進度符合畢業(yè)任務書要求，應能按時按量完成畢業(yè)設計。 簽名： 2018年 4 月 24日 中期情況檢查表 學院名稱： XX 檢查日期： 2018 年 4 月 26 日 學生姓名 XX 專 業(yè) XX 指導教師 XX 設計（論文）題目 PE400×600復擺顎式破碎機的設計 工作進度情況 確定了最終的設計方案，并且對破碎機的動顎部分進行了設計并繪制了零件圖，同時繪制了帶輪、肘板、飛輪、偏心軸等多個零件并對其進行了強度計算。 是否符合任務書要求進度 是 能否按期完成任務 是 工作態(tài)度情況 (態(tài)度、紀律、出勤、主動接受指導等) 態(tài)度認真，按時出勤，能夠積極主動的自主設計，不明白的也會主動詢問老師 質量 評價 (針對已完成的部分) 計算部分符合設計要求，圖紙基本可以表達結構特點 存在問題和解決辦法 說明書語言不夠嚴謹，圖紙圖線標注部分略有不標準的地方，后期根據畢業(yè)設計要求進行改正 檢查人簽名 教學院長簽名 Copyright by International OCSCO World Press. All rights reserved. 2007VOLUME 24ISSUE 1September2007Occasional paper405of Achievements in Materialsand Manufacturing Engineeringof Achievements in Materialsand Manufacturing EngineeringHigh precision machining on high speed machinesJ. Kopa* Faculty of Mechanical Engineering, University of Ljubljana, Askerceva 6, SI-1000 Ljubljana, Slovenia* Corresponding author: E-mail address: janez.kopacfs.uni-lj.siReceived 15.04.2007; published in revised form 01.09.2007Manufacturing and processingAbstrActPurpose: Modern Machines for precision products for three dimensional machining have by milling over 20.000 rpm. Differences between hard and soft machining have influences on concept of machines. Stiffness and rigidity are characteristics and variables which caused the precision and quality of machined part.Design/methodology/approach: This paper introduce some of interesting modern machine tools with different concept as DCG (Drive in Centre of Gravity - Mori Seiki), LAF (Look Ahead Function on machine - Sodick), high speed 20.000 60.000 rpm, linear drive, etc. The way from idea to machined part will be shown.Findings: To achieve high precision it is necessary to fill out many request function on machine. Results on machined part depend also from machined material (hardness, structure, size of crystals).Research limitations/implications: Engineers job is to prepare the optimal CNC (PNC) program on connection of CAD CAM softwares. After all mentioned factor test work piece is machined and measured.Originality/value: Comparison between results data on plan and measurement shows us the reality and give us decision around high precision product.Keywords: Manufacturing and processing; Machining; High speed machine tools; Precision machining; Precise products; Soft machining; Hard machining1. Introduction Some specifics of modern machine tool are included over modules, as rotation table, precise high RPM spindle, bar magazine, tools magazine, work pieces magazine, laser zero point measurement system, cutting forces dynamometer for diagnostic of process, frequencies sensor, acoustic sensors, etc., 1. To connect all modules in working action, the machine computer must be excellent. Softwares in computer as NN (Neural Network), GA (Genetic Algorithm), GP (Genetic Programming), LAF (Look Ahead Function), are assuring all time in machining process optimal cutting parameters 2, 3. Many of producers of cutting machine tools all over of the world provide machines in idle level of precision. To achieve precision production we need high level of machine quality. The highest quality caused also high price of machine. Top level ob machine price are 500.000 to 1.000.000 euros for more then three axis machine. 3axis milling machines and turn machines with driven tools are under 400.000 euros. Classical machining on little older machines - no modern high speed, is also very useful in individual production or in tool making industries. The prices of mentioned machines are under 200.000 euros. They are also mostly not able to achieve HS region. HS region is defined with more of elements, which will be shown in some of next chapter of this paper. 3D gravures polishing is very special job for achieving low surface roughness. Its time consumption technology, mostly handy made. That for it has to be automated with driven polishing tool and minimize with choice of special cutting technology. To ensure it is necessary to choice ball nose cutter, low depth of cut, small feed rate and very high speed. After technology are important maters software and controllers, where is include huge knowledge around complex optimization of cutting condition on base of self-learning controller 4,5. Automaticaly federate minimization is very usefull before finishing and polishing closing surfaces by 3D dies and moulds. 1. IntroductionOccasional paper406Journal of Achievements in Materials and Manufacturing EngineeringJ. KopaVolume 24 Issue 1 September 2007 2. Specifics of modern cutting machine tools Mentioned modules are also adaptable. Rotation table is more effective in the case of automated clamping device for work piece. Design and workmanship was realized 6. Figure 1 shows schematically concept to connect hydraulically control on clamping device - above. Below part of figure shows machine cell, powered and control over air and hydraulic medium. Fig.1. Schematically present of medium flow from source to palette on milling machine High productive are turn machines, which are shared in modern classical system on 60 support bed degree as horizontal and new concept of vertical turn machine, Figure 2. With driven tools equipped and both side spindle turn machine is high productive. With added axis as Z1, Z2 and C1, C2 is production 5-7x higher as on conventional lathe 7. Vertical turn machine is also new concept of intensive machining, where the chips have better flow away versus horizontal principle. On Figure 2 is concept with below the spindle with work piece. It is possible also opposite; to be spindle above and the cutting tools are moving over revolver and cascade tool clamping system. Machine like this is more rigid, more precise and high productive. Fig. 2. Horizontal turn machine tool with two revolvers, auxiliary spindle and Y axis and vertical turn machine tool Fig. 3. Robust horizontal machining centre Robust horizontal machining centre, Figure 3 shows rough concept of modules and structure more axis machine. B axis is so called axis nr.4. It gives possibility of complex shapes of 3D work piece. Machine is also more exacting and it is necessary to prepare effective programming engineer of machining. Simple managing from low educated worker gives not optimal machining time and also higher production costs. The latest turn machine bed is under angle 60 degrees. Angle like this on Figure 4, Figure 5 gives optimal solution for assumption of cutting force components 8. The vibrations are limited and chips flow is regulated as well. Schematically introduce below shows two spindles, two revolvers and driven cutters. With opposite side machining in same time make forces compensations. Fig. 4. Basic structure of horizontal lathe with two revolvers and auxiliary spindle revolver operation panelspindle revolver 2 opposite spindle chip transporter Fig. 5. Basic structure of horizontal lathe with two revolvers and opposite spindle Step more and the last model is multi axes machine. It is basically turn machine with all possible modules and axis. With right and left side of spindle is possible to finish the product on the same machine without logistics, double positioning and clamping. Milling spindle produce the shapes in complexity versus classical production on 7 different machines. milling spindle oposite spindle spindle revolver milling spindle Fig. 6. Multi axis turn- machining centre Working principles and controller of modern machine collect modules as shows Figure 7. Classical control was NC, after then CNC, but new one is CPU unit. All segments are connected with fast internet bus connection. High power electro motors are AC concept, digital servo motors. PLCfast internet bus conecton spindle drive digital AC servo motors axes drive X, Y, Z, B digital AC servo motors CAD/CAMethernet RS-232 memory card CNC CPU unit information machine server Fig. 7. Working principle of modern machine tool with CNC control with CPU technology 3. Precision machining; theory and principles Fine machining can be done on more ways, as classical fine cutting, smooth machining, rolling and finishing. Classical way was cutting with sharp cutting edge and small feed rate. Smooth 2. specificsofmoderncuttingmachinetools407Manufacturing and processingHigh precision machining on high speed machines 2. Specifics of modern cutting machine tools Mentioned modules are also adaptable. Rotation table is more effective in the case of automated clamping device for work piece. Design and workmanship was realized 6. Figure 1 shows schematically concept to connect hydraulically control on clamping device - above. Below part of figure shows machine cell, powered and control over air and hydraulic medium. Fig.1. Schematically present of medium flow from source to palette on milling machine High productive are turn machines, which are shared in modern classical system on 60 support bed degree as horizontal and new concept of vertical turn machine, Figure 2. With driven tools equipped and both side spindle turn machine is high productive. With added axis as Z1, Z2 and C1, C2 is production 5-7x higher as on conventional lathe 7. Vertical turn machine is also new concept of intensive machining, where the chips have better flow away versus horizontal principle. On Figure 2 is concept with below the spindle with work piece. It is possible also opposite; to be spindle above and the cutting tools are moving over revolver and cascade tool clamping system. Machine like this is more rigid, more precise and high productive. Fig. 2. Horizontal turn machine tool with two revolvers, auxiliary spindle and Y axis and vertical turn machine tool Fig. 3. Robust horizontal machining centre Robust horizontal machining centre, Figure 3 shows rough concept of modules and structure more axis machine. B axis is so called axis nr.4. It gives possibility of complex shapes of 3D work piece. Machine is also more exacting and it is necessary to prepare effective programming engineer of machining. Simple managing from low educated worker gives not optimal machining time and also higher production costs. The latest turn machine bed is under angle 60 degrees. Angle like this on Figure 4, Figure 5 gives optimal solution for assumption of cutting force components 8. The vibrations are limited and chips flow is regulated as well. Schematically introduce below shows two spindles, two revolvers and driven cutters. With opposite side machining in same time make forces compensations. Fig. 4. Basic structure of horizontal lathe with two revolvers and auxiliary spindle revolver operation panelspindle revolver 2 opposite spindle chip transporter Fig. 5. Basic structure of horizontal lathe with two revolvers and opposite spindle Step more and the last model is multi axes machine. It is basically turn machine with all possible modules and axis. With right and left side of spindle is possible to finish the product on the same machine without logistics, double positioning and clamping. Milling spindle produce the shapes in complexity versus classical production on 7 different machines. milling spindle oposite spindle spindle revolver milling spindle Fig. 6. Multi axis turn- machining centre Working principles and controller of modern machine collect modules as shows Figure 7. Classical control was NC, after then CNC, but new one is CPU unit. All segments are connected with fast internet bus connection. High power electro motors are AC concept, digital servo motors. PLCfast internet bus conecton spindle drive digital AC servo motors axes drive X, Y, Z, B digital AC servo motors CAD/CAMethernet RS-232 memory card CNC CPU unit information machine server Fig. 7. Working principle of modern machine tool with CNC control with CPU technology 3. Precision machining; theory and principles Fine machining can be done on more ways, as classical fine cutting, smooth machining, rolling and finishing. Classical way was cutting with sharp cutting edge and small feed rate. Smooth 3. Precisionmachining;theoryandprinciplesOccasional paper408Journal of Achievements in Materials and Manufacturing EngineeringJ. KopaVolume 24 Issue 1 September 2007 machining is modern way of cutting with big radius R on cutting edge. Fed rate is huge and remove rate is 8 x bigger. It is very important from view of machining time for achieve required surface roughness, Figure 8. required roughness Rth machining time t Fig. 8. Surface roughness quality versus machining time Cutting tool material has important influence on work piece surface roughness. Especially type of coating as TiN, TiCN, TiAlN caused lower toll wear, Figure 9. As result of minimal toll wear is toll life to achieve criteria of cutting edge changing. Movic as soft cutting caused good sliding phenomena, better tribology contact and better surface roughness. Ra achieved with mentioned tolls is significant lower as by inserts of tungsten carbides. Cutting speed m/min Tool life of cutter m no coating Fig. 9. Tool life of milling cutter carbide cutting tool material with different coatings Ball nose milling cutter is ideal cutting tool for fine machining. Phenomena of that pencil milling tools is possibility to cut work piece hardness to 62 HRc. Producers of cutting tools are able to produce diameter of cuter 0.5 mm with two flutes. Every cutting edge is very sharp and has very precise cutting angles. After machining time the cutting edges are weared, Figure 10. Normal, theoretical wear is on flutes, but middle part of cutter, it means central part can has also some breakages 9. The reason is in smaller cutting speed, where BUE is assist able 10. Tool wear and tool life depends of used cutting tool materials and Nr. of passes of tool over the machined surface. Tool wear W or VB is the best by coating TiAlN/TiN 11, Figure 11. Central wearTool flank wear Fig. 10. Different wear shapes on the pencil milling ball end nose Number of crossingsMedium wear W mm Fig. 11. Toll wear diagram based on middle of cutter After more experiments we carried out optimal solution for precise machining: It is multilayer coatings with last layer of TiN 12, which has very low tribological coefficient. Toll wear is minimal, as shows Figure 12. Normally the parameters of cutting must be defined as a= 0.1mm, f=0.05mm and cutting speed v = 150 - 200 m/ min. By small cutter diameter it is possible to achieve only on HS machine, which has 20.000 to 40.000rpm 13. Fig. 12. Tool wears on cutting edge Figure 13 shows toll wear of the free surface on the rounded tip of the milling tool which is quite big. The break down of the cutting edge is visible on the rounded tip of the milling tool. It is the case of wrong decision of machining parameters. Feed rate in this case was too high. To achieve bigger material remove is not feed rate right solution. It must stay small. Only with higher cutting speed we achieve bigger removal chip volume. Fig. 13.Toll wear on cutting edge by pencil cutter bed case 5. Polishing Last step by finishing of machined surface is polishing. It is useful only in the case, when geometry shape is not request to be in tolerances over 2 m. Polishing is very time consumption and using driven hand polishing tools is request. On this way polishing time is shorter, because vibrant power on polishing segment helped as well. Figure 14 shows last fine machining on closing surface by mould tool. With combination of precise milling, the polishing time was shorted from 16 hours to 3 hours. Fig. 14. Hand polishing of work piece with driving tool Using different diamante polishing gel help also to shorter the polishing time. Different gels are using for different materials. Hardness of polished surface and Ra request different size of diamante cons. Gel fluid and his viscosity is influencing on intensively/time of polishing, Figure 15. Fig. 15. Diamante polishing gel As mentioned above, vibrations powered polishing tools are very effective. Figure 16 shows polishing device with ultrasound powering frequency. It means from 14 to 21 KHz. Movements as this one can be danger for surface in case, when worker is not really concentrated on his obligation. Force on device has to be very gently in another case the surface can be damage over preheating, what caused recrystalization of surface layer. Fig. 16. Hand/driven/polishing of work piece with ultrasound device 6. Case study of precise and ability of machine Sodick Machining case study was carried out over the mould work piece product. Figure 17 shows schematically actions, which are necessary to achieve requested shape of product. As first was done design over one of CAD program. Input of design is new or old part with some changes. In that case RE Reverse Engineering is right way for quick preparing of CNC program. After CAD is CNC program created over CAM software. Missing is still jet post processing, where is for every machine tool controller a little bit another. Case of modern turn machine with integration of many modern modules shows Figure 18. Work pieces magazine is on left and strong control system is on right side of machine centre. Very right is toll magazine. 409Manufacturing and processingHigh precision machining on high speed machines machining is modern way of cutting with big radius R on cutting edge. Fed rate is huge and remove rate is 8 x bigger. It is very important from view of machining time for achieve required surface roughness, Figure 8. required roughness Rth machining time t Fig. 8. Surface roughness quality versus machining time Cutting tool material has important influence on work piece surface roughness. Especially type of coating as TiN, TiCN, TiAlN caused lower toll wear, Figure 9. As result of minimal toll wear is toll life to achieve criteria of cutting edge changing. Movic as soft cutting caused good sliding phenomena, better tribology contact and better surface roughness. Ra achieved with mentioned tolls is significant lower as by inserts of tungsten carbides. Cutting speed m/min Tool life of cutter m no coating Fig. 9. Tool life of milling cutter carbide cutting tool material with different coatings Ball nose milling cutter is ideal cutting tool for fine machining. Phenomena of that pencil milling tools is possibility to cut work piece hardness to 62 HRc. Producers of cutting tools are able to produce diameter of cuter 0.5 mm with two flutes. Every cutting edge is very sharp and has very precise cutting angles. After machining time the cutting edges are weared, Figure 10. Normal, theoretical wear is on flutes, but middle part of cutter, it means central part can has also some breakages 9. The reason is in smaller cutting speed, where BUE is assist able 10. Tool wear and tool life depends of used cutting tool materials and Nr. of passes of tool over the machined surface. Tool wear W or VB is the best by coating TiAlN/TiN 11, Figure 11. Central wearTool flank wear Fig. 10. Different wear shapes on the pencil milling ball end nose Number of crossingsMedium wear W mm Fig. 11. Toll wear diagram based on middle of cutter After more experiments we carried out optimal solution for precise machining: It is multilayer coatings with last layer of TiN 12, which has very low tribological coefficient. Toll wear is minimal, as shows Figure 12. Normally the parameters of cutting must be defined as a= 0.1mm, f=0.05mm and cutting speed v = 150 - 200 m/ min. By small cutter diameter it is possible to achieve only on HS machine, which has 20.000 to 40.000rpm 13. Fig. 12. Tool wears on cutting edge Figure 13 shows toll wear of the free surface on the rounded tip of the milling tool which is quite big. The break down of the cutting edge is visible on the rounded tip of the milling tool. It is the case of wrong decision of machining parameters. Feed rate in this case was too high. To achieve bigger material remove is not feed rate right solution. It must stay small. Only with higher cutting speed we achieve bigger removal chip volume. Fig. 13.Toll wear on cutting edge by pencil cutter bed case 5. Polishing Last step by finishing of machined surface is polishing. It is useful only in the case, when geometry shape is not request to be in tolerances over 2 m. Polishing is very time consumption and using driven hand polishing tools is request. On this way polishing time is shorter, because vibrant power on polishing segment helped as well. Figure 14 shows last fine machining on closing surface by mould tool. With combination of precise milling, the pol